Electrical connector for tapping power from an insulation covered conductor



m May M, 1%? M. A. SHERWUOE) ELECTRICAL CONNECTOR FOR TAPPING POWFIHFROM AN INSULATION COVERED CONDUCTOR Filed July 28, 1965 W Z f T NE E.N...

m m y m mm United States Patent 3,320,385 ELECTRICAL CONNECTOR FORTAPPING POWER $160M AN INSULATION COVERED CONDUC- R Henry A. Sherwood,Short Hills, N.J., assignor to US. Servicator Corporation, Clifton,N.J., a corporation of Delaware Filed July 28, 1965, Ser. No. 475,443Claims. (Cl. 200-129) The instant invention relates to electricalconnectors in general and more particularly to connectors of this typehaving an automatic splicing means for making electrical connection toan insulation covered electrical conductor at a point remote from theends thereof.

Today there are many accessory devices available for installation on avehicle or machine after the latter has left the factory. A great numberof these accessories are electrically operated and as a result must beconnected to the electrical system of the vehicle or machine inquestion. It often happens that a convenient mounting position for theaccessory is remote from electrical terminal points of the vehicle ormachine and in some cases even when the terminal points are inreasonably close proximity a special adapter is required for makingconnection thereto.

Practice has shown that the installer of such accessories as often asnot finds it more convenient to break into an electrical line at a pointremote from the ends thereof rather than to run a line to a terminalpoint. Heretofore this has required the stripping of insulation from theconductor in question, the making of an electrical connection theretoand then taping the joint to provide insulation. The foregoingprocedures are often inconvenient to perform in that the line beingtaped is often in a limited space. As a result the procedure is overlytime consuming and the quality of the splice is questionable as tocontact resistance and insulation quality.

Accordingly, a primary object of this invention is to provide a novelautomatic splicing means for making electrical connection to a conductorat a point remote from the ends thereof.

Another object is to provide an automatic splicing device which issimple to operate and of relatively inexpensive construction yet can bequickly attached to an electrical conductor to provide a high qualityelectrical connection that is mechanically strong.

Still another object is to provide a novel fused automatic splicingdevice.

These as well as other objects of this invention will become readilyapparentafter reading the following description of the accompanyingdrawings in which:

" FIGURE 1 is a schematic illustrating the manner in which an accessoryis electrically connected to the electrical system of an automobile byutilizing a fused automatic splicing means constructed in accordancewith the teachings of the instant invention.

FIGURE 2 is an exploded perspective of the fused automatic splicingmeans.

FIGURES 3 and 4 are longitudinal cross sections of the fused splicingmeans having the fuse removed with these cross sections being taken inplanes disposed at right angles to one another.

Now referring to the figures and more particularly to the schematic ofFIGURE 1. For purposes of illustration electrically operated accessory11 (FIGURE 1) has been selected as one for an automobile and isconnected to the battery thereof through the fused automatic splicer 20of the instant invention and the key operated ignition lock 12 of theautomobile in question.

Fused automatic splicer 20, as best seen in FIGURES 2 through 4,includes a three piece housing consisting of lower housing section 21,upper housing section 22 and cap 23 threadably mounted to the upper endof upper housing section 22. Housing sections 21 and 22 are hollowelongated generally cylindrical members, with lower housing section 21having transverse partition 24 and upper housing section 22 havingtransverse strut 25 formed integrally therewith. The wall thickness ofhousing section 22 is reduced below external shoulder 26 with thisreduced section having an outwardly extending annular protrusion 27positioned close to, but spaced from shoulder 26. Lower housing section21 is provided, near its upper end, with three angularly displacedinward projections 28 which cooperate with annular projection 27 toprovide means for releasably securing housing sections 21, 22 to eachother.

That is, housing sections 21, 22 are constructed of a relatively stiffresilient plastic material such as compression molded Bakelite. Whenhousing section 21 is moved downwardly along the cylindrical axisrelative to housing section 22 the engagement between protrusion 27, 28causes deformation of lower housing section 21 sufficient to permitprotrusions 28 to move below protrusion 27. In mounting housing section21 to housing section 22 the reverse action takes place and asprotrusions 28 move above protrusion 27, the former snap into thepositions illustrated to lock members 21, 22 together.

Housing sections 21, 22 cooperate to define main chamber 31 in theregion between partition 24 and strut 25. The region of housing section21 below partition 24 defines a lower chamber 32 while the region ofupper housing 22 above strut 25 defines upper chamber 33, the upper endof which is enclosed by cap 23. Lower terminal member 35, mounted tolower housing section 21, includes female type fuse terminal connector36 disposed immediately above partition 24 and terminal plug 37 disposedbelow partition 24. Terminal member 35 is mounted by passing plug 37downwardly through slot 38 in partition 24 until tangs 39 fall below thelower surface of partition 24. Since tangs 39 are resilient, they areinitially forced toward one another but once they pass through aperture38 they move apart to block upward movement of terminal member 35.

Upper terminal member 40 is mounted to upper housing section 22 and issecured thereto by member 50. Terminal member 40 includes female typefuse terminal connector 41 extending below strut 25. Fuse terminal 41 isbifurcated with the two sections thereof being on opposite sides ofstrut 25. The portion of member 40 above fuse terminal 41 includesupwardly extending knife-like projection 42 disposed centrally withrespect to four other upwardly extending projections '43. As will behereinafter explained, projection 42 is provided for the purpose ofpiercing the insulating covering 55 of accessories cable 59 to engageconductor 56 thereof so as to provide an electrical connection betweenconductor 56 and fuse terminal 41. Projections 43 are disposed adjacentthe walls of upper housing section 22 defining the passage 57 disposedperpendicular to the cylindrical axis and extending straight throughupper chamber 33.

Member 50 is an elongated element of generally U- shaped cross sectionhaving an elongated slot 51 in the web thereof. Piercing projection 42extends upwardly through slot 51. Disposed at opposite ends of member 50are four ears 52 which engage the walls defining through passage 57 andin so doing frictionally secure member 50 to upper housing section 22and restrict upward movement of upper terminal member 40 so as to retainthe latter in operative position.

Fuse 60 is normally disposed within main chamber 31 with the conductingferrules 61, 62 at the ends of insulating tubular housing 63 beingreceived by fuse terminals 36, 41 respectively. The end of insulatedconductor 64 remote from accessory 11 is provided with a female typeconnector 65 which is insertable into lower chamber 31 for releaseableengagement with terminal plug 37. Cap 23 is provided with a centrallydisposed inwardly extending post 23a which is positioned in alignmentwith piercing projection 42.

Fused automatic splicer 20 is utilized in the following manner. With cap23 removed, accessories cable 59 is inserted into through passage 57.Then cap 23 is threaded on to the upper end of upper housing section 22with radial wings 22a, extending outwardly from upper housing section22, being hand held to prevent undue strain being placed on cable 59 ascap 23 is screwed into place. As cap 23 moves down the lower edge ofdownwardly extending threaded skirt portion 23b thereof engagesinsulation 55 moving it downwardly into engagement with or past theserrations 53 at the upper edges of the U-arms forming member 50. Thispositions a portions of conductor 56 directly over piercing projection42. As the downward movement of cap 23 continues, post 23a thereofengages the portion of insulation 55 aligned with piercing projection 42through insulation 55 into firm electrical contact with conductor 56.Although not illustrated, in the case of larger diameter cable,serrations 53 firmly engage the cable insulation to stabilize the cablein centered position over projection 42 while cap 23 is being screwedinto position, and to form a good mechanical connection between splicer20 and the cable.

Thus, this invention provides novel splicer for conveniently tappingpower from an insulation covered wire at a point remote from both endsof the wire. While the splicer of the instant invention has beendescribed as being a fused device it should now be apparent to thoseskilled in the art that splicer construction may be modified byeliminating the fuse while retaining the features for positioning thecable and piercing the insulation thereof to make electrical connectionto the cable conductor.

Although there has been described a preferred embodiment of this novelinvention many variations and modifications will now be aparent to thoseskilled in the art. Therefore, this invention is to be limited, not bythe specific disclosure herein, but only by the appending claims.

The embodiments of the invention in which an exclusive privilege orproperty is claimed are defined as follows.

I claim:

1. Automatic splicing apparatus including housing means having a portiondefining a chamber with a through passage for receiving an insulationcovered conductor, electrical conducting means including a first sectionhaving a piercing means extending into said through passage, meanssecuring said first section to said housing means, first means mountedto said housing and extending into said chamber, second means operableto move said first means toward said piercing means and in so doingcause piercing means to electrically engage an insulation covered wirepositioned in and extending beyond both ends of said through passage;said portion including a threadably mounted cap to which said secondmeans is mounted; third means having an aperture through which saidpiercing means extends; said third means disposed within said chamberand positioned to engage insulation covering of different sizes of wireto maintain such wire aligned with said piercing means as said firstmeans moves toward said piercing means; said third means includingspaced arms extending toward said cap with each of said arms having afree edge with multiple projections of varying height.

2. Automatic splicing apparatus including housing means having a portiondefining a chamber with a through passage for receiving an insulationcovered conductor, said portion including a cap and a part having secondmeans threadably engaged with said cap, electrical conducting meansincluding a first section having a piercing means extending into saidthrough passage means securing said first section to said housing means,first means mounted to said cap and extending into said chamber, saidsecond means operable to move said first means toward said piercingmeans and in so doing cause said piercing means to electrically engagean insulation covered conductor positioned in and extending beyond bothends of said through passage, said housing means including anotherportion defining another chamber, said conducting means also including afuse disposed in said another chamber and having a first and a secondterminal, said first section including a first terminal means inreleasable engagement with said first terminal, said conducting meansfurther including a second section including second terminal means inreleasable engagement with said second terminal, an elongated member ofgenerally U-shaped cross-section disposed in said passage, said memberhaving an aperture in the web thereof, said piercing means extendingthrough said aperture, said member having a plurality of protrusionsalong the free edges of each of its U-arms positioned for engagementwith insulation covering a conductor extending through said passagewithout piercing this insulation and engaging a conductor coveredthereby, said protrusions acting to maintain such conductor aligned withsaid piercing means as said cap is threaded on to said part.

3. Apparatus as set forth in claim 2 in which the protrusions of each ofsaid U-arms are of varying height.

4. Automatic splicing apparatus including housing means having a portiondefining a chamber with a through passage for receiving an insulationcovered conductor, said portion including a cap and a part having secondmeans threadably engaged with said cap, electrical conducting meansincluding a first section having a piercing means extending into saidthrough passage, first means mounted to said cap and extending into saidchamber said second means operable to move said first means toward saidpiercing means and in so doing cause said piercing means to electricallyengage an insulation covered conductor positioned in and extendingbeyond both ends of said through passage, said housing means includinganother portion defining another chamber, said conducting means alsoincluding a fuse disposed in said another chamber and having a first anda second terminal, said first section including a first terminal meansin releasable engagement with said first terminal, said conducting meansfurther including a second section including second terminal means inreleasable engagement with said second terminal, said housing meansfurther including a transverse partition separating said chamber andsaid another chamber, said first terminal means integrally formed withsaid piercing means, third means having an aperture through which saidpiercing means extends, said third means disposed Within said chamberand positioned to engage insulation covering of different sizes of wireto maintain such wire aligned with said piercing means as said firstmeans moves toward said piercing means, said third means includingretaining means frictionally engaging said housing means, said thirdmeans positioned to retain said first section of said electricalconducting means mounted to said housing means.

5. Automatic splicing apparatus including housing means having a portiondefining a chamber with a through passage for receiving an insulationcovered conductor, electrical conducting means including a first sectionhaving a piercing means extending into said through passage, first meansmounted to said housing and extending into said chamber, second meansoperable to move said first means toward said piercing means and in sodoing cause said piercing means to electrically engage an insulationcovered wire positioned in and extending beyond both ends of saidthrough passage; said portion including a threadably mounted cap towhich said second means is mounted; third means having an aperturethrough which said piercing means extends; said third means disposedWithin said chamber and positioned to engage insulation covering ofdifferent sizes of wire to maintain such Wire aligned with said piercingmeans as said first means moves toward said piercing means; said thirdmeans including retaining means frictionally engaging said housingmeans, said third means positioned to retain said first section of saidelectrical conducting means mounted to said housing means.

References Cited by the Examiner UNITED STATES PATENTS 1,369,874 3/1921Ayotte 339--220 2,440,748 5/1948 Johnson 3 39-99 2,491,463 12/1949Brooks 33999 6 2/1954 Gerlat ZOO-115.5 1/ 1955 Benander 33999 4/1958Sundt 200129 8/1958 Spataro 33999 4/1963 Brown et al 200115.5 4/1963Wright 200-166 2/1966 Louden et al. 200-129 FOREIGN PATENTS 4/ 1938Australia. 9/ 1963 Great Britain.

BERNARD A. GILHEANY, Primary Examiner. H. B. GILSON, Assistant Examiner.

1. AUTOMATIC SPLICING APPARATUS INCLUDING HOUSING MEANS HAVING A PORTIONDEFINING A CHAMBER WITH A THROUGH PASSAGE FOR RECEIVING AN INSULATIONCOVERED CONDUCTOR, ELECTRICAL CONDUCTING MEANS INCLUDING A FIRST SECTIONHAVING A PIERCING MEANS EXTENDING INTO SAID THROUGH PASSAGE, MEANSSECURING SAID FIRST SECTION TO SAID HOUSING MEANS, FIRST MEANS MOUNTEDTO SAID HOUSING AND EXTENDING INTO SAID CHAMBER, SECOND MEANS OPERABLETO MOVE SAID FIRST MEANS TOWARD SAID PIERCING MEANS AND IN SO DOINGCAUSE PIERCING MEANS TO ELECTRICALLY ENGAGE AN INSULATION COVERED WIREPOSITIONED IN AND EXTENDING BEYOND BOTH ENDS OF SAID THROUGH PASSAGE;SAID PORTION INCLUDING A THREADABLY MOUNTED CAP TO WHICH SAID SECONDMEANS IS MOUNTED; THIRD MEANS HAVING AN APERTURE THROUGH WHICH SAIDPIERCING MEANS EXTENDS; SAID THIRD MEANS DISPOSED WITHIN SAID CHAMBERAND POSITIONED TO ENGAGE INSULATION COVERING OF DIFFERENT SIZES OF WIRETO MAINTAIN SUCH WIRE ALIGNED WITH SAID PIERCING MEANS AS SAID FIRSTMEANS MOVES TOWARD SAID PIERCING MEANS; SAID THIRD MEANS INCLUDINGSPACED ARMS EXTENDING TOWARD SAID CAP WITH EACH OF SAID ARMS HAVING AFREE EDGE WITH MULTIPLE PROJECTIONS OF VARYING HEIGHT.